Tufted rug



NGNL 211 M330 A. J. CARTER ET AL TUFTED RUG Filed Jan. 13. 1931 2 Sheets-Sheet l INVENTORS 409057 J. CARTER M/NA 51170105 1111111111111,-IIIIIIIIII A TTORNE Y A. J. CARTER ET Nov, 21,

TUFTED RUG Filed Jan. 13. 1931 2 Sheets-Sheet iv Mm l mm mm WW I mm INVENTORS Aueus T J CARTER BY MINA S. DUKE {QM KM ATTORNEY Patented Nov. 21, i933 NETED STATES t an? v r-ATENT OFFlCE TUFTED RUG August J. Carter and Mina S. Duke, Chattanooga, Tenn, 'a'ssignors to Carterv Brothers, Inc., Chattanooga, Tenn, a corporation of Tennessee Application January-13, issi. Serial No. 508,446 31 Claims. 02. 2-278)- a base material cut with square or angular corhers. The stitches extend through the base and beyond it upon one side to provide loops upon the upper surface, which loops may be cut to form a cut pile. The yarn is usually applied in several rows of stitches which extend around the angular periphery of the backing and longitudinal rows oi. stitches filling the enclosure thus formed.

It has been found, however, that when a backing of this shape is used and when the yarn used for tufting the rug is a wool or artificial silk yarn, the corners of the rug will not lie fiat upon the floor but will curl up and so become unslightly and otherwise objectionable. Furthermore, when a rug backing cut with square or an- 'gular corners is used in making this type of rug, the row of tufts extending around the periphery oi the backing will leave exposed comers which are unsightly in the finished rug.

It is an object of our invention to produce a rug of the above type which will not have these objectionable features and one which will lie flat upon the iioor. Another object is to provide a rug having rows of stitching which will completely hide the backing and in which the corners of the backing will not be exposed to view in the finished rug. A further object of the invention is'to provide an improved rug backing for use in making tufted rugs. Other objects will become apparent.

Ii a piece of material having rounded corners is usedas the backing in the production of tufted rugs, the yarn may be stitched around the periphery of the rug and through the enclosure thereby formed, to produce a smooth surface of pile and the finished rug will lie fiat upon the floor without curling at the corners even though the yarn used is of artificial sill; or wool. Furthermore, we have found that by stitching the backing so as to form rows of stitching extending around the periphery of the rug and inwardly from thecorners thereof, the corners will be even less liable to curl.

In describing our invention, reference will be U made to the drawings in which Figure l is a bottom plan view of my improved backing for use in producing a tufted rug. Figure 2 is a fractional rear plan view of the completed rug (omitting the lines of stitching illustrated in Figure l) and with a. corner of the rug turned back to illustrate the top surface of the rug. Figure 3 illustrates a fractional cross sectional view of the completed rug. Figure 4 is a fractional back plan view of a corner oi our improved backing with the edge surged.

Figure 5 is a irectional side elevation of a corner of our improved rug with the edge of they backing surged. Figures 6 and 7 are frictional back plan views of modified forms oi. our improved backing.

In the several figures of the drawings the nu-.

meral l designates the backing which may be made up of from one to three or more thicknesses of heavy material, such as duck or burlap. These several layers of material are cut to form rounded corners and are then sewn together by one or more rows of stitching 2, extending around the periphery of the backing. Several rows of stitching, indicated at 3, are run around the periphery of the backing, for example, there may be six or eight rows of stitching extending around the edge of the rug. This may be conveniently done with a multiple needle sewing machine of standard type for sewing an ordinary chain stitch.

At each corner of the backing, several rows of stitching, for example, six or eight, are run inwardly diagonally from the corner for a short distance as indicated at 4. Longitudinal rows of stitching illustrated at 5 may be added to hold the layers together throughout their middle portion. Y

After the backing 1 has been stitched as described above, the yarn used in forming the tufts is applied, as described in the Carter Patent No. 1,485,213, preferably by stitching through the backing from the same side as the stitching illustrated in Figure l and in such a manner as to provide several rows of tufted yarn, as illustrated at 6, extending around the periphery of the rug and'longitudinal rows 7 of tufts to fill in the enclosure within the rows 6. The loops formed as the needle passes through the backing may be cut to provide a pile such as illustrated at d in Figure 3, as described in my aforesaid patent, or, if it is preferred, the loops may be left uncut to form looped pile rather than the cut pile illus-= trated in Figure 3. The rows of cut loops should be close enough together to provide a continuous surface of tufts, as indicated at 8.

In stitching the rows of yarn a slightly ribbed effect may be produced in the tufted surface by sewing two rows of stitching spaced apart a distance less than the width of the presser foot of the stitching machine and thereafter sewing arow of stitching between these two rows. Since the rug base is compressed to a greater extent by the pressure of the presser foot upon the two first mentioned rows of stitching-the subsequent expansion of the rug base to its normal thicbriess will cause the intermediate row of tufts to become slightly shorter than the rows on each side of it and so will produce a ribbed appearance in the upper surface of the finished rug.

In producing a rug as described above, the outer row of stitching, extending around the periphery of the backing, will be spaced equidistant from the edge of the backing at all points and will not leave exposed corners of the backing in the finished rug, as would be the case when a backing having square or angular corners is used in producing this type of rug. In the production of this type of rug the yarn used in preparing the tufts is necessarily coarse in order that it may be unraveled and tufted. When such yarn is sewn through a backing material and along the edges thereof, it has a tendency to force the edge of the material outwardly and to elongate the same, thereby causing the edge of the rug to buckle or wrinkle when placed upon the floor. By applying rows of stitching around the edge of the rug as herein described, the edge is reinforced or stiffened so that its elongation is inhibited and the edge of the rug will lie fiat -upon the fioor.

The edge of the backing above described may be over-edged or surged as illustrated in Figures 5i and 5 by sewing rows of stitching 8', 8' extending from points spaced inwardly from the edge of the backing on each surface thereof toward the middle of the edge and forming a chain of stitches 9 extending around the rug at the middle of the edge. This surging assists, together with the curved corners and rows of stitching, in keeping the rug from buckling and to assure its lying fiat upon the fioor even after stitching of artificial silk or wool yarn has been applied as described. If desired, the surging may be of the same color as the yarn used to produce the surface of the rug or it may be of contrasting color and will, in any event, completely conceal the edges of the backing.

When a rug of large dimensions is made rows of stitching 10 may extend across the rows 4 as indicated in Figures 6 and '7, thereby further improving the lying qualities of the corners of the rug.

Although we have described our invention as particularly useful in the production of rugs using wool or artificial silk. yarn, it is apparent that it may be used to advantage also with rugs made from other yarns and will improve the lying qualities of such rugs. The terms used in describing my invention are used in their descriptive sense and not as words of limitation and it is intended that all equivalents of these terms be included within the scope of the appended claims.

What we claim is:

1. In the production of a tufted rug, the steps comprising sewing rows of stitching around the edge of a material having rounded corners, applying rows of stitching extending inwardly from the comers of the rug and tufting the rug by stitching rows of yarn around the edge of the backing and filling in the enclosure with rows of stitches of tufted yarn.

2. In the production of a tufted rug, the steps comprising uniting a plurality of layers of material to form a backing having rounded corners and sewing a plurality of rows of stitching around the backing near the edges of the layers, and tufting the rug by stitching a row of yarn through the backing near its edge and filling in the en-' closure with rows of stitches of yarn extending through the backing, and unraveling the yarn sewn through the backing to form tufts.

3. In the production of a tufted rug, the steps comprising uniting a plurality of layers of material to form a backing by sewing a plurality of rows of stitching around the layers near their edges, applying rows of stitching extending inwardly from the corners of the backing and tufting the rug by stitching rows of yarn around the backing near its' edge and filling in the enclosure with rows of stitches of tufted yarn.

4. In the production of tufted rugs, the steps comprising uniting a plurality of layers of material having rounded corners to form a backing by sewing a plurality of rows of stitching around the backing near the edges of the layers, applying rows of stitching extending inwardly diagonally from the corners of the backing and tufting the mg by stitching rows of yarn around the backing near its edge and filling in the enclosure with rows of stitches of tufted yarn.

5. A backing for a rug comprising a layer of material having rounded corners with rows of V stitching extending around the backing near the edge ofthe material and rows of stitching extending inwardly from the corners of the backing.

6. A backing for a rug comprising a plurality of layers of heavy closely woven material having rounded corners sewn together by a plurality of rows of stitching extending around the backing near the edges of the layers to provide a zone at the edge of the backing reinforced against lateral expansion. v

'7. A backing for a rug comprising a plurality of layers of material sewn together by a plurality of rows of stitching extending around the backing near the edges of the layers and having additional rows of stitching at the corners of the layers.

8. A backing for a rug comprising a. plurality of layers of material having rounded corners,sewn together by a plurality of rows of stitching extend- 11g ing around the backing near the edges of the layers and having rows of stitching extending diagonally inwardly from the corners of the layers.

9. A rug having a backing of material with rounded corners and with rows of stitching extending around the backing near the edge of the material androws of stitching extending inwardly from the corners of the material; and having rows of tufts of yarn stitched around the edge of the backing and rows of tufts of yarn filling in the portion of the backing enclosed thereby.

10. A rug having a backing of a plurality of layers of material with rounded corners and sewn together by stitching extending around the layers near their edges, and having rows of tufts of yarn stitched through the backing extending around the edge of the backing and rows of tufts of yarn stitched through the backing filling in the portion of the backing enclosed thereby.

11. A rug having a backing made up of a plurality of layers of material sewn together by a plurality of rows of stitching extending around the edge of the material and by rows of stitching extending inwardly from the corners of the mateof yarn filling in the portion of the backing enclosed thereby.

12. A rug having a backing made up of a plu rality of layers of material having rounded corners 14g sewn together by a plurality of rows of stitching extending around the edges of the layers and by rows of stitching extending diagonally inwardly from the corners of the layers, and having rows of tufts of yarn stitched around the edge of the backing and rows of tufts of yarn filling in the portion of the backing enclosed thereby.

13. A rug having a backing made up of a plurality of layers of material sewn together by a plurality of rows of stitching extending around 50 near the edges of the layers and by surging extending around the periphery of the layers, and having rows of tufts of yarn stitched through the backing extending around the edge of the backing and rows of tufts stitched through the backing filling in the portion of the backing enclosed thereby.

14. A rug having a backing made up of layers of material having rounded corners and sewn together by rows of stitching extending around near the edge of the material, and having rows of tufts of artificial silk yarn stitched through the backing extending around the edge of the backing and rows of tufts of yarn stitched through the backing filling in the portion of the backing enclosed thereby.

15. A rug having a backing made up of layers of material sewn together by rows of stitching extending around near the edge of the material and by rows of stitching extending inwardly from the corners of the material, and having rows of tufts of artificial silk yarn stitched around the edge of the backing and'rows of tufts of yarn filling in the portion of the backing enclosed thereby.

16. A rug having a backing made up of layers of material having rounded corners and sewn together by rows of stitching extending around near the edge of the material, and having rows of tufts of wool yarn stitched through the backing extending around the edge of the backing and rows of tufts of yarn stitched through the backing filling in the portion of the backing enclosed thereby.

17. A rug having a backing made up of layers of material sewn together by rows of stitching extending around near the edge of the material and by rows of stitching extending inwardly from the corners of the material, and having rows of tufts of wool yarn stitched around the edge of the backing and rows of tufts of yarn filling in the portion of the backing enclosed thereby.

18. A rug. having a backing with a plurality of rows of stitching extending around the backing near the edge of the material and having additional rows of stitching at the corners thereof, and rows of tufts of yarn extending from and covering a surface of the backing.

19. A rug having a backing with rows of stitching extending around the backing near the edges thereof and having rows of stitching extending diagonally inward from the corners thereof, and rows of tufts of yarn projecting from one side of the backing material.

20. A rug comprising a backing made up of a plurality of layers of material sewn together and having rows of stitching extending inwardly from each corner, and rows of yarn sewn through the backing and tufted to cover one surface thereof.

21. A rug comprising an angular backing with rounded corners, having rows of stitching extending inwardly from each corner, and rows of yarn sewn through the backing and tufted to cover one surface thereof.

22. A rug comprising a backing having rounded corners and a plurality of rows of stitching extending around the edge thereof, and having rows of tufts of yarn stitched through the backing extending around the edge of the backing and concentric with the corners thereof and rows of tufts of yarn stitched through the backing filling in the portion of the backing enclosed thereby.

23. A rug comprising a backing made up of a plurality of layersof material having rounded corners and sewn together by stitching extending around the layers near their edges, and having rows of tufts of yarn stitched through the backing extending around the edge and concentric with the corners thereof and tufts of yarn stitched through the backing filling in the portion of the backing enclosed by the said row of tufts.

24. A rug comprising a backing made up of a plurality of layers of material having rounded corners and sewn together by stitching extending around the layers near their edges, and having rows of tufts of wool yarn stitched through the backing extending around the edge and concentric with the comers thereof and tufts of wool yarn stitched through the backing filling in the portion of the backing enclosed by the said row of tufts.

25. A rug comprising a backing made up of a plurality of layers of material having rounded corners and sewn together by stitching extending around the layers near their edges, and having rows of tufts of artificial silk stitched through the backing extending around the edge and concentric with the corners thereof and tufts of artificial silk stitched through the backing filling in the portion of the backing enclosed thereby.

26. An angular rug comprising a backing of heavy closely woven material with rounded cor ners, having a row of tufts of coarse yarn stitched through the backing near the edge thereof C011? centric with the corners and closely following the contour of the backing at the corners and having tufts stitched through the-.backing filling the portion of the backing enclosed by said row of tufts.

27. An angular rug comprising a backing made up of a plurality of layers of heavy closely woven material and having rounded corners, a row of stitches of coarse yarn, of the class including wool and artificial silk, through the backing near the edge thereof concentric with the corners and closely following the contour of the backing at the corners, and stitches of such yarn filling in the space within said row, said yarn being tufted to cover a surface of the backing.

28. A rug comprising a backing having rounded corners and a plurality of rows of stitching extending around the edge thereof and having rows of tufts of yarn stitched through the backing extending around the edge of the backing and rows of tufts of yarn stitched through the backing, filling the portion of the backing enclosed thereby.

29. A rug as defined in claim 28 having a backing made up of a plurality of layers of material sewn together.

30. A backing for a rug comprising a plurality of layers of heavy closely woven material having rounded corners sewn together by rows of stitching extending around the backing near the edges 

